Flexible wrapper handles multiple pack styles and counts

Visitors to interpack 2014—which opens this Thursday, May 8, in Dusseldorf, Germany—will be among the first to see a new packaging system for biscuits (cookies in the U.S.) from Bosch Packaging Systems AG that takes flexibility in running different pack styles and counts to a lofty level. In this exclusive Packaging Digest video, Daniel Bossel, Bosch product manager, shows the main features of the new line that will be showcased in Hall 06 / A31 at interpack.

Bossel also answered our questions about the benefits of the new line:

How is this new biscuit packaging system different from previous or competitive systems?

Bossel: Bosch’s biscuit packaging system is the first of its kind capable of fast slug to pile changeovers, and vice versa, with the same feeding components. Designed for maximum flexibility, the line also features the fastest product count changes currently available on the market. Enabling biscuit manufacturers to meet global market demands, the system is capable of producing multiple pack styles, from smaller on-the-go packages to larger family packs. As the first complete system capable of producing slug and pile packs on the same line, it is truly two-in-one.

What were the challenges in designing the system to gain new levels of flexibility and fast changeover? How were these challenges solved?

Bossel: We listened to customer needs to help biscuit manufacturers capitalize on opportunities in the industry. Designing for optimum format and pack style flexibility was the biggest challenge. This meant engineering the line to package both slug and pile packs from one infeed.

By using the same feeding components, fully reproducible changeovers between both pile and slug packs can be completed in less than three minutes without changing parts. In addition, count changes, for example, from 14 to 8 biscuits per slug or from two-by-two to two-by-four piles, can be realized in less than one minute. This allows manufacturers to quickly run special promotions with maximum uptime.

Complementing primary packaging, the biscuit line is designed for versatile case packing, which can be adjusted quickly and easily to the required format and product configuration with vertical start-up.

How does the design allow for quick and easy cleaning?

Bossel: Designed for simplified cleaning, the biscuit line offers high visibility and accessibility for areas requiring sanitation, as well as belts that are simple to clean and replace. Gentle product handling technology decreases product breakage, waste and clean up, resulting in high overall equipment effectiveness (OEE). The system also features three-dimensional product inspection technology to reject broken biscuits. This prevents crumbs from accumulating throughout the system, which allows a continuous product flow and maximized production uptime.

How can food companies best use this system to its optimum performance?

Bossel: From distribution to secondary packaging, the entire line has been holistically designed as one seamless system. To facilitate high OEE, the speed of all line components is balanced to eliminate bottlenecks, minimize downtime and optimize production flow. It is designed with the operator in mind, with the same look and feel across the entire line, including one human machine interface (HMI) and standard operating procedures. This integrated design concept makes operation of the entire system as simple as operating a single machine, which reduces the risk of operating errors and maximizes uptime.

As one system capable of producing both pile and slug packs, the entire biscuit packaging line occupies a smaller footprint than two separate conventional machines for both formats. This allows manufacturers to save on production costs through reduced maintenance and man-hours.

What is the value of introducing this system to the packaging industry at interpack?

Bossel: Interpack is the world’s leading trade fair for packaging technologies. This allows for the greatest gathering of customers from across the globe to see the new system that will benefit their needs and achieve production goals.